AMMONIA COOLING TOWER - INTRODUCTION

Introduction
Ammonia Cooling Tower is an Induced Draft cross flow type supplied by
M/s Paharour Cooling Towers, having 2 hot return water distribution
decks, one on each side.
Both the decks have got six cells and one induced draft fan is installed in
the centre at the top of the Tower for each pair of cells.
Total Length of C.T. 80.67 Mtrs.
Height at Distribution Deck 13.63 Mtrs.
Height at fan Deck 14.43 Mtrs.
Total 24600 M3/Hr. Cooling Water is supplied to Ammonia Plant through
3 Nos. C.W. Pumps each having a capacity of 8200 M3/Hr.
Hot Cooling Water from Ammonia Plant after exchanging heat returns
through a common header and rises to the top of distribution deck
through 2 separate risers of 52 dia. for each deck.
From the risers, hot cooling water enters the distribution decks through
distribution headers having diameters reducing from 48 in first cell to
20 in last cell.
 AMMONIA COOLING TOWER - INTRODUCTION

Distribution header is supported on wooden saddles mounted directly on

main wooden columns at a distance of 4 feet and has provision to isolate
individual cell.
All the structural members of cooling tower are made of wood and fills
are made of PVC material. All the decks are joined together with the help
of cross members and diagonals.
The tower is balanced by means of diagonals provided in the tower
structure beneath the distribution deck.
Load carrying vertical wooden members of the tower structure is
mounted on RCC Columns erected in the basin and RCC basin wall.
Some of the wooden columns and diagonals are anchored with RCC work
at the bottom whereas others are just resting.
A VIEW OF COOLING TOWERS
 AMMONIA COOLING TOWER FAILURE

Damages Observed
Southern half of Ammonia Cooling Tower collapsed in the night of 23 rd
April. Tower components were lying on ground outside and inside the
tower.
Part of southern portion of Ammonia CT which was still erect, was found
leaning towards east because of damage to some cross members holding
the same
North side distribution deck and header was intact.
Fan deck was intact and all the fans were found running without any
indication of abnormality as observed from ground level.
52 dia. South side riser was bent towards east side and bulged at the
bottom.
3 FRP line for Chlorine dosing was completely damaged.
Return header had fallen & found to be broken in two pieces. The
damaged pieces were found to be severely deformed.
Part of the return header had fallen on the RCC Column inside the basin
damaging five RCC Columns.
31
 AMMONIA COOLING TOWER FAILURE

Event
At around 23:45 hrs on 23rdApril 2002, entire south side wooden structure
of Ammonia Cooling Tower covering the six cells, collapsed along with
return header. Fans, structure to support the fans and other side of the
cooling tower, were intact. Since heavy loss of water was taking place, it
was not possible to maintain water level in the cooling tower sump.
Ammonia & Urea plants had to be stopped immediately.
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 AMMONIA COOLING TOWER REPAIR

Actions taken to Restore Ammonia CT for Plant Operation

The debris was removed carefully to avoid any damage to intact portion of
Cooling Tower because of debris removal
Distribution header were strengthened by providing patches in the lower
half of the pipe from inside by making an opening in upper half.
Patches on pipe were provided from outside also as per need.
Part of distribution header was replaced with new pipe.
To save time, all damaged diagonals for CT were replaced with diagonals
made of reclaimed material using metallic connectors made in workshop.
All long diagonals were repaired by replacing damaged members.
North side portion of Tower structure was inspected and damaged
columns were rectified.
All fans were inspected and found OK.
Damaged RCC columns were recast.
Basins of both Cooling Towers were connected by a 1.7 m dia pipe
 AMMONIA COOLING TOWER REPAIR

Actions taken to Restore Ammonia CT for Plant Operation

South side risers of Ammonia CT was connected with south side riser of
Urea CT by a 24 dia pipe to divert part of ammonia CT to Urea CT for
better cooling.
Southern part of cooling tower was partly covered with tarpaulin sheet to
reduce bypassing of air.
Outer sleeve of distribution nozzles were removed to enhance water
handling capacity.

Possible Reasons of Break Down

Explosion due to presence of hazardous gases
Water hammering
Shearing of pipe due to thinning
Sudden failure of main supporting columns
 AMMONIA COOLING TOWER FAILURE

Analysis
None of the exchangers in Ammonia plant were found leaking. Hence,
possibility of explosion is ruled out.
As the plant was running consistently without any change in the
parameters, possibility of water hammering is also ruled out.
Though we have observed thinning of pipe, the thickness was intact in the
upper parts. As the pipe has sufficient thickness in more than 50%
cross-section, sudden shearing of pipe can not take place. Hence,
possibility of breakdown due to sudden shearing of pipe is also ruled out.
Sudden failure of main supporting wooden columns appears to be the
most probable reason of failure. This might have resulted in breaking of
distribution header leading to collapse of particular tower cell due to
hydraulic loading and mechanical impact. This will result in failure of
other cells as well.
M/s. PCT has taken wood samples for analysis. We are also sending
damaged wood to some independent laboratory for analysis to assess the
strength of failed material.
 COOLING TOWER - MAINTENANCE PRACTICES

Maintenance Practices
Sl. No. Existing Proposed
Fortnightly vibration measurement Vibration measurement of fans on
1
of all the fans weekly basis.
Annual Preventive maintenance of Shall Continue
2
fans, gearbox, motor.
Annual Inspection & repair of Shall Continue
3 cooling tower timber structure by
PCT personnel.
Need based patch repair of Bottom half shall also be taken care
distribution headers, mostly in of by providing patch from inside.
4
upper half. Need based replacement of
distribution headers shall also be
Need based painting of Shall Continue.
5
distribution header
Vibration measurement of return
6
water headers on weekly basis.
 AMMONIA COOLING TOWER REPAIR

Monitoring Practices Adopted for Running of Ammonia CT

Water was charged in cooling tower keeping a watch on pipeline
vibrations.
Fans were started one by one. Second fan was started only after vibration
measurement of the fan already running. Vibrations of all fans were OK.
Daily monitoring of vibrations of Fans and Pipeline.

Inspection Practices for Timber Structure

Developing internal skills for Cooling Tower inspection to reduce
dependence on OEM personnel for Cooling Tower inspection.
Developing checklist for inspection of Tower Timber Structure and in-
house inspection in running by isolating cells one by one.
Inclusion of 100 % items affecting efficiency & stability of Cooling Tower,
in scope of inspection
100 % inspection of the job performed by OEM Repair Team.